Building construction



D. E. ROSS BUILDING CONSTRUCTION BUILDING CONSTRUCTION Jam. M, 1214 Filed Feb. 4, 1935 4 Sheets-Shem: 2

Jan. 14, 1936. o. E. ROSS BUILDING CONSTRUCTION Filled Feb. 4, 1935 4 Sheets-Sheet 4 4 a 2 J w 6. "w W 6 %a n fl M 5% Patented Jan. 14, 1936 UNITED STATES BUILDING coNs'rnoc'rioN David E. Ross, La; Fayette, Ind; assignor to Rostone, Incorporated, La Fayette, Ind a corporation of Indiana Application February 4, 1935. Serial No. 4,963

12 Claims.

This invention is an improvement in walls, buildings, or the like, and the present invention is an improvement upon that shown in my copending application Serial No. 701,380 filed December 7, 1933. The principal objects of the invention are to provide novel means for attaching wall blocks of pre-molded blocks of stone or other materials to such walls, buildings, or other structures, also means for weatherproofing the joints; all parts of the wall blocks and weatherstripping being so designed and related that an architect by the use of stock ore-fabricated parts can apply same to walls or buildings of various forms and dimensions, to give various external appearances and finishes thereto, said stock parts being readily assembled and erected by unskilled labor. The framing of the wall, building, or other structure may be made of wood, metal, or other material, and my novel blocks may be readily applied directly over the exterior surface of old walls or buildings without first removing the former surfacing. v

Other advantages and novel features of the invention are hereinafter referred to; and to facilitate a full understanding of the novelty and utility of. the invention I will explain the same with reference to the accompanying drawings which show the essential parts and features of construction. In the claims the novel features of construction and combinations of parts for which protection is desired are summarized.

In said drawings:

Fig. 1 is a perspective View of a sectionof a wall having a steel framing, and showing my novel .pre-formed blocks applied thereto.

Fig. 2 is an enlarged perspective view showing thestrap connecting the uppermost courses of blocks at'opposite sides of the wall.

Fig. 3 is a perspective view of a section of the galvanealed track for the blocks, showing the punchings to accommodate the stud spacings, and also the punchings which register with the holes in the blocks.

Fig. 4'is an enlarged section on the lined-4, Fig. 3.

Fig. 5 is an enlarged section through the track showing a typical horizontal joint between courses of blocks.

Fig. 6 is a-sectional view showing my exterior wall blocks applied to the exterior of a steel frame building.

Fig:-7 is an enlarged perspective view showing the connection of the tracks to the vertical wall studs of Fig.6, and showing the blocks associated with the track.

Fig. 8 is a view similar to Fig. 7 but showing the tracks and block applied to a building having studdings formed with metallic nailing strips.

Fig. 9 is a sectional View similar to Fig. 6 but showing the exterior wall blocks applied to a 5- wooden frame building.

Fig. 10 is an enlarged perspective view similar to Fig. '7, but showing the track applied to the vertical stud of Fig. 9.

Fig. 11 is a sectional View similar to Figs. 6 and 9, but showing the exterior slabs applied to the exterior surface of an old building.

Fig. 12 is a perspective view similar to Figs. 7 10 showing the furring strips applied to the shingles of the old building. shown in Fig. 11, and showing the track secured to the furring strips, and the associated Wall blocks.

Fig. 13 is a perspective view of a section of the spline used for sealing the vertical joints between blocks.

Fig. 14-. is a section through a typical vertical joint showing the spline and waterproofing mastic in the joint.

Fig. 15 is a view showing the method of insertingthe splines in the vertical joints.

Fig. 16 is a view similar to Fig. 15 but showing the spline seated in place.

Fig. 17 shows a typical section through a jamb; Fig. 18 is a typical section through a transom head; and Fig. 19 a typical section through a sill.

Fig. 20 is an elevation of a wall formed with modified blocks.

Fig. 21 shows a wall in which the alternating courses of blocks are of different-heights; and

Fig. 22 shows a wall in which the courses of blocks are of three or more different heights.

In Fig. 1 a wall is shown having a bottom plate I and an upper plate 2, preferably both channel irons, connected by vertical studdings 3 which are also preferably channel irons connected together in any suitable manner. The wall section shown has an inside corner i shown at the right side of Fig. 1, and has an outside corner 5 shown at the-left side. Both faces of 45 the wall are covered with pre-molded blocks A to G, each course of blocks being supported upon longitudinally disposed pre-fabricated tracks 6 consisting of galvanealed angle bars provided with punchings 1 (Figs. 3, 4, 5) on their vertical 50 legs to suit the spacing of the studdings 3, and each track 6 being secured to the studding by bolts la; (Figg'?) or by rivets or the like.

Figs. 3 and 4 show perspective and sectional views of track 6. Each section of track is made 55 about fourteen feet long but may be varied in length to suit the stud spacings, and has a vertical flange 6a provided with the punchings l, and has a horizontal flange 6b with a longitudinally disposed vertical offset portion 60, the outer end of which is rolled downwardly as at 6d for purpose of determining the horizontal spacing between courses of blocks. In the horizontal flange 6b adjacent flange 6a are weep holes 6w spaced about six inches apart which allow any condensate which may collect on back of the blocks A-H and collect on track member to to run down the wall to the foundation (Fig. 5) thus eliminating the danger offreezing in the joints and of corrosion of the track.

In the offset portion 60 are spaced punchings 8 to suit the spacing of the holes A, G in the upper and lower edges of the wall blocks AG, which blocks are supported on the tracks 6 as hereinafter described. As shown in Fig. 5, the registering holes A'G, and punchings 8 receive dowel pins 9 which look the blocks upon the tracks.

At intervals of about two feet a pair of spaced holes 89 (Figs. 1 and 3) are punched in offset portion 60 of the track to accommodate the holes G in the outside corner blocks G (Fig. l) as hereinafter described. The downwardly rolled or bent portion 6d of the horizontal leg 6b of the tracks 6 not only determines the horizontal spacing of the courses of blocks but also clamps and secures the underlying block AG, preventing vibration, due to the frictional engagement of the sharp lower end of the portion (it! with the top end of the underlying block.

Each regular block A, has spaced holes A in its upper and lower edges to suit the spacing of the punchings 8 in tracks 6. These holes A are of a depth substantially equal to half the length of the pins 9 which lock the blocks in place on the tracks. Also each half-size regular block D is provided with the spaced holes D in its upper and lower edges.

Each inside corner block E has holes E in its upper and lower edges spaced the same distance apart as the holes in block A. Block E is provided with a beveled edge E on one side to form with a similarly beveled edge on the adjacent block a mitred inside-corner joint. Each halfsize inside-corner block F is also provided with the spaced holes in the upper and lower edges and has a beveled edge on one side.

Each outside corner block G has holes G in its upper and lower edges. This block G has both vertical edges beveled as at G to a point, from both the front and rear faces, as indicated so that the interior beveled face will abut the end of the adjacent block, and the exterior beveled face will form a continuation of the outer face of the adjacent block.

The wall (Fig. 1) is made up of pro-fabricated or pre-molded blocks A to G and as shown the major portions of the courses are made up of the full-size regular blocks A, the half-size regular blocks D being utilized to eifect the breakjoint arrangement between adjacent courses. At the outside corners 5 of the wall are blocks G. The punchings in tracks 6 for the outside corner blocks G are provided for by the spaced pairs of holes 8g (Figs. 1 and 3) in the horizontal legs of the tracks 6 which pairs of holes are located at approximately two-foot intervals in the tracks. A length of track which is to be cut to fit the outside corner of a building would be cut through the mid-point of a pair of holes 8g,

viz. on the dotted line 8:0 Fig. 3, and when the sections of the track thus severed are secured to the wall or studding the holes 8g will be aligned vertically with the holes G in the upper and lower ends of the outside corner blocks G 5 as indicated in Fig. 1. At the interior corners 4 the full-size blocks E or the half-size blocks F are used. The coping consists of the regular coping blocks B and at the corners of the coping the corner coping blocks C are used, both of which blocks B and C are provided with holes on their undersides to suit the spacing of the dowel pins 9.

In forming the wall the lowest track 6 shown at the right of Fig. 1 is secured to the studdings 3, said track being provided with fixed dowel pins 9 projecting upwardly above the raised portion 60, and the lowest course of blocks A, E, G, etc. are placed upon the lower track 6 with the pins 9 in the lower track entering the pre-drilled 20 holes A'G etc. in the lower ends of the blocks. The next higher track 6 is then placed over the upper edges of the lower course of blocks, and the pins 9 dropped through the punchings 8 in the upper track and into the holes AG, in the 25 upper edges of the lower course of blocks; and the upper track then secured to the studdings 3 of the wall. The above operation is repeated for all successive courses. Preferably a little mastic M (Fig. 5) is inserted in the holes A'G' in the blocks to seal the pins in the holes. The pins 9 are of sufficient length to fill the registering holes A'G so that each pin will lock the upper ends of the blocks of a lower course and the lower ends of the blocks of an upper course to 35 tracks 6, as clearly indicated in Fig. 5.

The uppermost courses of blocks preferably terminate flush with the upper plate 2 of the wall framing as shown in Figs. 1 and 2; and preferably transversely disposed straps I 0 (Fig. 2) are provided secured to the upper plate 2 by nails, rivets, or the like extending beyond the sides of the plate, and having punchings Illa disposed in alignment with the perforations A'G' in the upper edges of the blocks to receive pins 9 similar to the pins of the tracks 6 projecting above the straps l0 and entering the perforations B, C in the lower faces of the coping blocks B and C.

The track sections 6 may form a continuous support for the blocks over a window and/or door opening as shown in Figs. 17-18; and the sill blocks H for the windows are likewise provided with spaced holes in their lower edges for receiving the pins 9 of the supporting tracks 6 (Fig. 19).

While Fig. 1 shows walls of the parapet type, my invention is obviously applicable to other structures. Fig. 6 shows a vertical section through a typical house or building having studdings 3 of steel channel irons extending between lower plate I and the upper plate 2. The lower plate I is mounted upon a suitable foundation I3, and the building is provided with the usual joists I4, l5 and I6 for supporting the floors, and with rafters H for supporting the roof. The exterior of the building is covered with the slabs A-I-I, as previously described, mounted upon tracks 6 securely bolted, riveted or fastened by such connections shown in my U. S. Letters Patent Nos. 1,986,980, 1,986,981, dated Jan. 8, 1935, to the studdings 3 as shown more particularly in Fig. 7, the tracks being provided with the same holes 8 and 89' for receiving pins 9 which 75 754,508 filed November 23, 1934, for receiving and retaining the nails la: which secure the tracks 6 to the studs 3r. The blocks A-G are supported in the tracks 6 and locked thereto bypins 9 in the same manner as in Fig. '7.

Fig. 9' shows the blocks A, etc., applied to a building having wooden studding 3 carrying the joists l4 and I6, and carrying the rafters H. The blocks A, etc., are mounted upon the tracks 6 as shown more particularly in Fig. 10, the tracks being secured by'nails la or other means to the studdings 3, and provided with the holes 8 for the pins 9 which enter the holes in the upper and lower edges of the blocks AH.

Fig. 11 shows the application of my wall blocks directly over the exterior surface of an old building. In this modification vertically disposed furring strips 20 (Fig. 12) are nailed or otherwise secured directly over the shingles 2| or other siding, or may be nailed directly over the sheeting 22 which is supported by the studs 23; and the tracks support the slabs AH in the same manner as previously described. If desired, shims 200. (Fig. 12) may be used between the furring strips 28 and the tracks 6 where necessary for the purpose of vertically aligning the tracks.

The vertical joints between slabs are sealed by use of novel splines 24 (Figs. 13-16) which are preferably formed of bronze or other non-rustable sheet metal, the metal being bent back upon itself along its longitudinal axis 25 and the outer edges of the legs being flared outwardly as at 26 to form a resilient compressible spline which when compressed may be inserted in the vertical spaces between blocks. The width of said spaces are regulated by the spacing of the holes 88g for the pins 9 and the holes in the blocks. When the splines 24 are inserted as shown in Fig. 14,

their outer flaring edges 26 will frictionally engage the ends of adjacent blocks, and the compressed spline will thus be frictionally held in the openings so that when the mastic M (Fig. 14) is subsequently applied to waterproof the vertical joints the splines 24 will form a back-stop for the mastic and will prevent same from passing through the rear of the joint.

The splines 24, as shown in Figs. 2 and 25, are preferably of length to suit the spacing between tracks 6 and the upper and lower ends of each spline is preferably rounded as shown at 24a (Figs. 15-16) to conform with the shape of the horizontal leg of the track 6 so that the upper end will fulcrum on the downwardly curved lip 6d of the upper track 6 when the spline is compressed and pushed inwardly into the joint with the aid of a tool similar to a putty knife; and the spline will be prevented from passing entirely through the opening by reason of the downwardly curved lip 2th at the lower end of the spline which conforms with the curved lip 6d of lower track 6.

My spline is placed in the joint before the joint is calked and serves as a stop against which the calking presses. The spline is not embedded as the calking touches only one side- It is not necessary to use a hard setting mortar in the joints of my wall construction. A calking compound only may be used, thus eliminating the disadvantages of mortar.

Fig. 17 shows a typical enlarged section through a jamb illustrating the arrangement of blocks with relation to the outer trim of the jamb. Fig. 18 a typical section through a head; and Fig. 19 a typical section through a window sill, 10 the flashing 30 under the sill having its outer end bent downwardly and entering a longitudinal recess H in the upper beveled edge H of the sill block.

Fig. 20 shows a wall built up of blocks similar .15 to blocks A to G, but certain of the blocks are provided with false joint grooves A disposed at various angles and positions in the outer faces of the blocks to give the appearance oi mortar joints, thus breaking the regularity of the de-go sign of the Wall shown in Figs. 1 and 2.

In Fig. 21 the design of the blocks is varied by giving the alternating courses of blocks two different heights; and in Fig. 22 the design is further modified by giving the courses of blocksrzb more than two different heights. The design or pattern of blocks in the wall may be varied so that the vertical joints can be brdken, or a more modernistic design can be had by placing the blocks directly one over the other to give a con-'80 tinuous vertical joint as well as a continuous horizontal joint. In so doing the strength of the wall is not sacrificed by not having the interlock feature of the blocks overlapping as the strength of the Wall is not dependent structurallyxifl upon the arrangement of blocks or joints. The blocks are merely a storm coat hung upon the wall studdings.

The use of the blocks AG will permit building any parapet wall or flat-roof type of house with regular walls. In order to adapt the blocks to a house having a gable roof it wil only be necessary to give the necessary edges of the blocks AG the desired pitch of the gable.

The blocks A-H are accurately drilled and are furnished directly by the factory as are also the accurately punched tracks 6; and it is therefore possible to ship from the factory finished material which may be erected quickly and easily with unskilled labor as great skill and care ares not required on the part of the mason in erecting the wall.

The spacing of the pins and holes in the tracks and blocks is such that the vertical joints between blocks in the same course are automatically taken care of and the horizontal joint between courses is automatically taken care 01' by the thickness of the track, the outer'lip 01' the track being curved downwardly to engage the upper ends of the blocks of the lower course and to give the correct horizontal joint thickness; also the outer downwardly curved edge 6d 01' the track serves as a backing to prevent the mastic M or other packing from running backwardly in the joint between the stones.

The advantages of spaced relationship between pre-punched holes in the tracks, and pre-drilled holes in the blocks are that the shape of track 6 provides a joint of predetermined thickness, and maintains a uniform horizontal joint, and adds to the strength of the supporting member; also the punching of track and the drilling of stone gives a smooth wall surface, and spaces the stone uniformly out from the wall, and gives a square and true wall which is accurate as to 75 length and height. It is also an aid to the ease of erection in that the location of each block is predetermined; and the vertical joints are maintained uniform by the clearance allowed for the size of stone. Another advantage of my construction is that it is not necessary to sheathe or cover the stud structure in order to obtain a means to fasten the block supporting members or tracks to the frame.

I do not herein claim specifically the block supporting track 6, or the waterproofing spline 24, or the blocks AH per se, as these features form subject matter of divisional applications.

I claim:

1. In a wall construction; a frame, a horizontal series of spaced parallel pre-fabricated members mounted upon the frame, each member having a portion projecting substantially normal to the wall with spaced wall engaging members thereon courses of pre-formed blocks seated upon their respective projecting portions and filling 'the spaces between adjacent members, said blocks having spaced pre-drilled holes in their upper and lower edges adapted to receive the wall engaging members of the projecting portions.

2. In a wall structure as set forth in claim 1, the thickness of said projecting portions determining the horizontal spacing of the courses of blocks.

3. In a wall structure as set forth in claim 1, said projecting portions terminating in rear of the exterior faces of the blocks and filling the rear portions of the spaces between blocks, and waterproofing in the front portions of the spaces.

4. In a wall structure as set forth in claim 1, the thickness of said projecting portions determining the horizontal spacing of the courses of blocks, said projecting portions terminating in rear of the exterior faces of the blocks, and waterproofing in the spaces in front of the projecting portions.

5. In a wall structure as set forth in claim 1, means for waterproofing the vertical joints between blocks in the same course.

6. In a wall structure as set forth in claim 1, the spacing of the wall engaging members of the projecting portions and the pre -drilled holes in the blocks determining the vertical spacing of the blocks in the courses.

7. In a wall structure as set forth in claim 1,

said blocks including standardized full and fractional length slabs whereby the blocks in adjacent courses may have a vertical break joint arrangement.

8. In a. wall structure as set forth in claim 1, 5 said blocks including standardized full and fractional length regular slabs; standardized full and fractional length inside corner slabs; and standardized outside corner slabs, whereby the blocks in adjacent courses may have a vertical break 10 joint arrangement.

9. In a wall structure as set forth in claim 1, the adjacent courses of blocks being of different heights.

10. In a wall structure as set forth in claim 1, 5 said blocks being applied to both faces of the frame with the upper courses terminating adjacent the top of the frame; pre-fabricated straps on the top of the frame having wall engaging members adapted to engage the holes in the 20 upper edges of the blocks; and means over the straps covering the upper edges of the blocks and frame.

11. In a wall structure as set forth in claim 1, said blocks being applied to both faces of the 2 frame with the upper courses terminating adjacent the top of the frame; pre-fabricated straps mounted on the topof the frame having wall engaging members adapted to engage the holes in the upper edges of the blocks; and coping 30 blocks covering the upper edges of the blocks and frame and having pre-drilled holes in their under sides receiving the wall engaging members.

12. In a wall structure having courses of blocks,

a spline for waterproofing the vertical joints be- 35 tween blocks comprising a substantially U- shaped resilient member, the legs of the member being fiared outwardly to yieldably engage the ends of adjacent blocks when the member is inserted within the joint, said courses of blocks bem ing supported upon tracks having their outer edges rolled downwardly to determine the horizontal spacing between courses, and said splines being of length to suit the spacing between tracks, the upper and lower ends of the spline being shaped to conform with the rolled edges of the tracks whereby when the spline is inserted in the joint the lower end thereof will be prevented from passing through the joint.

DAVID E. ROSS. 

